Textile apparatus and method for transversely aligning pattern marks



United States Patent Allan 11. Crawford Amsterdam, N.Y.

Nov. 16, 1967 Dec. 29, 1970 Mohasco Industries, Inc. Amsterdam, N.Y.

a corporation of New York inventor Appl. No. Filed Patented Assignee TEXTILE APPARATUS AND METHOD FOR TRANSVERSELY ALIGNING PATTERN MARKS 14 Claims, 15 Drawing Figs.

US. Cl. 112/79, 66/132, 156/72, 250/219, 112/266 1nt. Cl. D05: 15/34 Field 01 Search 1 12/2, 2A,

2D, 79, 79.6, 266; 66/125, 86A, 132; 250/219S, 219(lnquired); 324/68, 69, 70; 28/1, 55.5, 4, 72.2; 26/515; 156/72 DANCING ROLL SENSING DEVICE Primary Examiner-James R. Boler Attorney-Joseph P. Flanagan ABSTRACT: A method and apparatus for controllably feeding a preprinted plurality of yarns to a pile forming apparatus to insure transverse registration of the pattern printed on such yarns.

YARN BE AM 5 TUFTER CONTROL PULgES seusms'PuLses INDEX YARN TUFTED PRODUCT WINDER FOR INDEX. YARN PATENTEDDEQQIQYB 3.550.543

SHEET 1 BF 8 DANCING ssusms 7 ROLL DEVICE YARN YARN v BYEAARPSIS TUFTER TUFTEKD PRODUCT CONTROL PULSES YARN iFEED {CONTROL SENSINGVPULSES musx YARN WINDER FOR W INDEX YARN INVENTOR ALLAN H. CRAWFORD ATTORNEYS Pmmmmzsmn 3.550543 SHEET 2 BF 8 I l llllllllfll INVENTOR ALLAN H. CRAWFORD SHEET 3 BF 8 INVENTOR ALLAN H. CRAWFORD TEXTILE APPARATUS AND METHOD FOR TRANSVERSELY ALIGNING PATTERN MARKS The present invention relates to a method and apparatus useful in the manufacture of pile fabrics, such as floor coverings or the like, having precise colored designs formed thereon.

In the manufacture of certain types of pile fabric floor coverings, for example tufted fabrics, the methods and apparatus heretofore known for forming color designs therein have proved to be far short of what is desired. The methods previously employed to form color designs in such fabrics have taken the form of screen printing, stenciling, spraying, reservoir dyeing, etc. In all of these approaches, as will be well appreciated by those familiar with the art, it has proved virtually impossible to produce a fabric wherein the outlines of the various colors of the design could be clearly delineated, while at the same time having the various dyes penetrate as deeply into the pile as desired.

My approach to the problem of forming color designs in tufted pile fabrics, although it departs considerably from those avenues followed in the past, has proved quite satisfactory and is capable of forming such colored designs having the qualities heretofore sought but not attained in the manufacture of such products, namely, excellent delineation of the outlines of the various parts of the design and excellent penetration of the various color dyes into the pile.

A reading of my copending application Ser. No. 684,055, filed Nov. 17, 1967, of even date herewith will disclose the manner in which a beam of yarn may be prepared on which is wound a sheet of yarns having a lengthwise repeating pattern thereon. Also wound on such beam is what I term an index yarn, that is, a yarn having regularly recurring lengthwise stretches colored with a dye sharply contrasting in color with the base color of such index yarn. The leading edge of each such index mark may be spaced from the leading edge of its adjacent index marks a distance equal to the length of the pattern repeat of the pattern printed on the aforesaid sheet of yarns wound on such beam, and each such leading edge of each index mark is placed in the same position lengthwise of the pattern on each sheet of yarns wound on the various beams.

In forming a tufted carpet utilizing yarns printed according to the teaching of my aforementioned patent application, I simultaneously feed the sheet of printed yarns contained on two or more beams to the needles of a tufting machine. That is to say, assuming the sheet of yarns on each beam is composed of I44 ends of yarn, and I want to tuft an approximately foot wide roll of ;-inch gauge carpet, I would take ten such beams, each of which contained a sheet of yarns having a pattern printed on it, and simultaneously feed such 10 beams to the needles of the tufting machine, making sure that the pattern was accurately aligned transversely of the machine at the start of the tufting operation.

In withdrawing the yarn from the plurality of beams, all of the yarns on any one beam will generally be withdrawn at the same rate and the pattern printed on such sheet should tend to be accurately reproduced in the carpet being tufted. It may happen, however, that the sheets of yarn on all 10 beams will not be withdrawn at the same rate. Should such an event occur, serious problems would prevail in obtaining accurate registration of the pattern in the transverse, i.e. weftwise, direction of the tufted product.

The primary object of the present invention is to make possible the feeding, to the needles of a tufting machine, of a plurality of sheets of yarns from a plurality of beams as nearly uniform as possible to insure proper transverse alignment, in the tufted fabric, of patterns appearing on such beams. This object is achieved by apparatus which monitors the aforementioned index yarn wound on each such beam, as it is withdrawn therefrom, and controls the rate of speed as necessary of certain groups of yarns to bring all the yarns being fed to the control into propertransverse alignment, that is, to properly align transversely the printed pattern appearing on each beam of yarns.

A plurality of sensing devices are carried by the tufting machined and each such index yarn, which yarn, incidentally, is not utilized as one of the pile forming yarns of the product being tufted, is passed through its associated sensing device as such yarn is withdrawn from its beam. The sensing devices are aligned transversely of the tufting machine and means is provided to determine if an index mark on each of the index yarns is passing through the monitoring zone simultaneously or nearly so.

If each sensing device senses an aligned index mark substantially simultaneously with each other sensing device, and, of course, this is the condition desired, the withdrawal of yarn from each beam continues thereafter at what is termed a normal rate. Should each sensing device not, however, detect an index mark simultaneously, provision is made for corrective action to be taken to adjust the rate of yarn withdrawal from the various beams to bring them back into synchronization.

The above-mentioned primary object, as well as further objects and advantages of this invention will be readily apparent from the following detailed description taken in connection with the accompanying drawings, wherein:

FIG. I is a block diagram representation of the present invention;

FIG. 2 is a side view of the yarn beam apparatus of FIG. 1;

FIG. 3 is an elevation view ofthe tufter of FIG. 1;

FIG. 4 is a front view of the'sensing device of the instant invention;

FIG. 5 is an elevation view of the tufting machine of FIG. 3',

FIG. 6 is a block diagram of the sensing and control device of the instant invention;

FIGS. 7, 8, 9, 10, and 10A are input-output tables showing the inputs and outputs of the various components of FIG. 7;

FIG. 11 is a timing diagram;

FIGS. 11A, 12 and 13 illustrate the circuitry of the sensing and control device of FIG. 6.

A supporting framework 50, FIG. 2, located in the floor area adjacent to a tufting machine supports a plurality of shafts 51, 52, 53, 54, etc. journaled in bearings carried by the framework 50. Each of such shafts is fitted with a knurled collar 55 at each end. Respective pairs of these shafts, such as the pair of shafts 51, 52 support a beam of yarn 60 on the knurled collars 55. The shaft 52 is coupled in any well known means to a motor 61 by a suitable clutch 62 and is driven by said motor. The shaft 51 is connected to and driven by the shaft 52 by means of an endless chain trained around sprocket wheels (not shown) carried by each of the shafts 51, 52. The clutch 62 is controlled by limit switches, not shown, operated by lugs secured to a chain 63 operatively associated with a dancing roll 64, the operation of which is well known in the art. Each of the other beams supported by the framework 50 is similarly supported and driven to provide a reservoir of yarn, in the area of its associated dancing roll, to be withdrawn therefrom by feed rolls as hereinafter described.

As above mentioned, in tufting, say, a 15-foot wide carpet from yarn contained on beams such as the beam 60 of FIG. 2, a plurality of such beams would be fed in synchronization to the tufting machine 70 of FIG. 3. The tufting machine 70 is similar in construction and operation to conventional tufting machines heretofore known in the art. The instant machine, however, utilizes apparatus to control the rate of feed of yarns to adjacent zones of such machine, a zone of the machine being defined herein as the width of the tufting machine required to tuft into a backing sheet all the ends of yarn, with the exception of an indexyarn, contained on one of the beams 60.

The yarn from each one of the beams 60 passes through tubes 71, leading from the framework 50 to a frame member 73, FIG. 3, mounted on the tufting machine. As the yarn emerges from the tubes 71 it is threaded through a guide member 74, a sensing device indicated by the arrow I10, a second guide member 75, and then around a pair of feed rolls 78, 79 carried by shafts journaled in bearings on frame mem bers 72, 72, etc. There is a separate pair of feed rolls for each zone. The feed rolls 78, 79 withdraw yarn from the reservoir created by the action of the dancing roll 64, and present such yarn to the needles of the tufting machine.

The No. 1 zone of FIG. is designated a master zone. In operation, the yarns for this zone are fed to the tufting machine at what will be termed a normal rate, and if the yarns feeding any or all of the other zones, such as the No. 2 zone, the No. 3 zone, etc., are fed at such a rate that the feed of those yarns gets out of synchronization with the feed of the yarns of the No. 1 zone, the feed of the yarns for such other zones will be retarded or accelerated to bring them into synchronization with the yarnsof zone No. 1. In certain instances, if the index marks of any other zone or zones are too far out of synchronization with the master zone, no corrective action will be taken to advance or retard the feed of yarns to such other zone or zones, but an alarm will be actuated to inform the operator of the tufting machine of such out of synchronization condition.

The tufting machine 70 is driven by a main drive shaft 76 conventionally coupled to and driven by a motor 77. Any suitable reducing means between the main shaft 76 and an auxiliary drive shaft 80, FIGS. 3 and 5, may be utilized to drive said auxiliary drive shaft.

The auxiliary drive shaft 80 is coupled to and drives three shafts, a normal or average shaft 81, a retard shaft 82, and an accelerate shaft 83 by means of a suitable gearing arrangement in a gear box 84. In my embodiment, the coupling between shafts 80 and 81 is the ratio 1:1, the ratio between shafts 80 and 82 is 100:98, and the ratio between shafts 80 and 83 is 98: 100, but such ratios could, of course, vary. Carried by the normal shaft 81 in zone No. 1 is a conventional magnetic clutch 85 which, when energized, couples the shaft 81 to a sprocket wheel 88 loosely carried by the shaft 81. In zone No. 1, additional sprocket wheels 89 and 93 are loosely carried on studs fixed to the frame member 72' and sprocket wheels 95, 96 are secured to the shafts carrying the feed rolls 79 and 78 respectively, of zone No. 1. An endless chain 98 is suitably trained around the sprocket wheels 88, 89, 95, 96, and 93, in that order, to drive the feed rolls 79 and 78 in clockwise and counterclockwise directions, respectively, FIG. 3, when the tufting machine is in operation.

The shafts 80, 81, 82, and 83 are of a length extending the full width of the tufting machine, while the shafts carrying the feed rolls 78, 79 are each of a length equal to the width of a single zone such as zone No. 1, zone No.2, etc. of FIG. 5.

In all the zones of the tufting machine other than zone No. 1, the shafts 81, 82, and 83 carry clutches similar to the aforementioned clutch 85, which clutches, when energized, couple such shafts to sprocket wheel similar in structure and operation to the sprocket wheel 88. In each such zone, that is, zones No. 2, 3, etc., a sprocket wheel such as the wheel 102 is loosely carried by a stud mounted in the machine framework. Additionally, the shafts carrying the feed rolls 78, 79 of each zone are equipped with sprocket wheels similar to the sprocket wheels 96, 95 of zone No; 1.

In zones No. 2, 3, etc., an endless chain 104 is trained around the sprockets carried by the shafts 82, 81, and 83, the sprockets carried by the feed roll supporting shafts, and the sprocket wheel 102 so that, when any one of the clutches of any such zone is energized, the associated feed rolls will be driven in opposite directions to feed yarn to the needles of the tufting machine. Whenever any one of the clutches of zone No. 2 is energized, the other two clutches in such zone are deenergized, as described below.

In connection with the above description of the zone No. 1 drive mechanism, it may be that it will at times be found desirable to provide the shafts 82 and 83, within zone No. 1, with clutches similar to the clutches 82a and 83a of zone No. 2 to allow the feed rolls of zone No. 1 to be driven at a speed faster or slower than the speed of the normal shaft 81. In such a case, the drive arrangement of zone No. 2 may be suitably adapted to zone No. 1. v

Mounted on and located between the guides 74, 75 in each zone, FIG. 3, is the aforementioned sensing device indicated by the arrow and more clearly shown in FIG. 4. This sensing device consists of a transparent tube 112 suitably secured to the guide members 74, 75 which tube has a pair of photosensing devices 114, secured adjacent thereto. Each sensing device essentially comprises a light source 114a and a photocell 114b capable of detecting whether the portion of yarn reflecting light from the light source 1140 is, for example, white or black.

As the yarn feed rolls withdraw yarn from each beam, the index yarn withdrawn therefrom is passed through the tube 112 of the sensing unit located in the zone served by such beam, and then around the feed rolls 78, 79 of such zone. Such index yarn then bypasses the needles and is passed through a guide 116, FIG. 5, to any suitable takeup device not shown. For the purpose of the description that follows, I designate the photocells of the sensing device of any slave zone, i.e., zones No. 2, 3, etc., as a first photocell and a second photocell, the first photocell being the photocell of any sensing device past which the index yarn first passes and the second photocell being the photocell past which the yarn subsequently passes. Accordingly, in FIG. 4, the photocell 11411 is the first photocell and the photocell 115b is the second photocell.

FIGS. 6-13 illustrate the sensing and control device associated with the master zone No. 1 and the slave zone No. 2.

Referring now to FIG. 6 the first and second slave photosensors 114b and 115b sense the index mark on the slave index yarn and apply a BLACK pulse to the slave logic decoder 132 if they sense an index mark, and a WHITE pulse to the slave logic decoder 132 if they do not sense an index mark. The first and second master photosensors 114b and 115b' sense the index marks on the master index yarn and apply a BLACK pulse to the master logic decoder when they sense an index mark and a WHITE pulse when they do not sense an index mark. The master logic decoder applies a speed evaluate pulse to the slave logic decoder 132 when an index mark is sensed on the master index yarn by both the first and second master photosensors 114b and 115b' and applies a reset attempt pulse to the reset gate 131 under the same conditions. The slave logic decoder 132 applies a yarn slow pulse to the clutch selector 138 when only the first slave photosensor 1141: senses an index mark on the slave index yarn at the same time that a speed evaluate pulse is applied thereto, and applies a yarn fast pulse to the clutch selector 132 when only the second slave photosensor l15b senses an index mark on the slave index yarn at the time that a speed evaluate pulse is applied thereto. When neither of the slave photosensors sense the index mark, a no-go pulse is applied to the alarm 134. Normally no reset inhibit pulse is applied to the reset gate 131. A reset inhibit pulse is applied to the reset gate only when neither of the slave photosensors sense an index mark.

The rest gate 131 normally applies a reset pulse to the clutch selector 138 when a reset attempt pulse is applied to the reset gate.

The clutch selector 138 produces a retard clutch signal, an accelerate clutch signal, or an average clutch signal depending on what input signals are applied to the clutch selector 138 from the reset gate 131 and the slave logic decoder 132 in a manner to be described. The generation of one of the three clutch signals in a manner to be described selects one of the three clutches to either accelerate the feeding of the save zone yarns, retard the feed of the slave zone yarns, or maintain the feed of the slave zone yarns at their average rate of feed.

The operation of the control shown in FIG. 6 operates to control the rate of feed of yarns to the various zones of the tufting machine in the following manner. The control may react in various ways in its attempts to maintain the feed of slave zone yarns in synchronism with those of the master zone. It will maintain the average clutch of the slave zone energized if the slave yarn is in synchronism with the master yarn, it will accelerate the slave yarn if the slave yarn is slower than the master yarn, and it will retard the slave yarn if the slave yarn is faster than the master yarn. If the slave yarn and the master yarn are in synchronism, both the first and second slave photosensors 11412 and 11517 will sense an index mark on the slave index yarn at the same time that the first and second master photosensors 114b' and 115b' sense an index mark on the master index yarn. The master logic decoder 130 will produce a speed evaluate pulse and a reset attempt pulse. The slave logic decoder 132 reacts to the sensing of an index mark by both of the slave photosensors and the receipt of a speed evaluate pulse by producing no signal. The reset attempt pulse from the master logic decoder 130 is passed by the reset gate and applied to the clutch selector 138. The clutch selector 138 responds to the reset pulse and the receipt of no pulse from the slave logic decoder by selecting the average clutch to maintain the feed of the master and slave yarns in synchronism.

If the slave index yarn is moving too fast at the time that the first and second master photosensors 114b and lb sense the index mark on the master index yarn, only the second slave photosensor l15b senses the index mark on the slave index yarn as the index mark has already passed the first slave photosensor 11%. Therefore only the second slave photosensor 1151: applies a BLACK signal to the slave logic decoder 132 at the time that the master logic decoder 1130 applies a speed evaluate pulse to the slave logic decoder 132. In response to the speed evaluate pulseand the BLACK signal from the second slave photosensor 115b, the slave logic decoder applies a yarn fast pulse to the clutch selector 138. The clutch selector 138 responds to the yarn fast pulse by selecting the retard clutch to slow the speed of the slave index yarn down, and try to bring the slave index yarn back into synchronism with the master index yarn. The retard clutch will remain energized until the next index pulses on the master and slave index yarns are sensed to determined if the slave and master index yarns have been brought back into synchronism. Depending on what relation the index marks on the slave and master index yarns have at that time, corresponding action will be taken. If the slave index yarn is in synchronism with the master index yarn at that time as indicated by the two slave photosensors 114!) and l15b producing BLACK signals at the same time that the two master photosensors 11412 and 115b produce BLACK signals, the average clutch will be selected as previously described. If the slave index yarn is too fast, the retard clutch will be selected again, and if the slave index yarn is too slow, the accelerate clutch must be selected.

If the slave yarn is moving too slow at the time the first and second master photosensors 11% and 115b' sense the index mark on the master index yarn, only the first slave photosensor 1l4b senses the index mark on the slave index yarn as the index mark on the slave index yarn has not yet reached the second slave photosensor l15b. Therefore only the first slave photosensor 115b applies a BLACK signal to the slave logic decoder 132 at the time that the master logic decoder 130 applies a speed evaluate pulse to the slave logic decoder 132. In response to the speed evaluate pulse and the BLACK signal from the first slave photosensor 11412, the slave logic decoder applies a yarn slow pulse to the clutch selector 138. The clutch selector I38 responds to the yarn slow pulse by selecting the accelerate clutch to speed up the feed of the slave yarn, and try to bring the slave yarn back into synchronism with the master zone yarn. The accelerate clutch remains energized until the next index marks on the master and slave index yarns are sensed to determine if the slave and master yarns have been brought back into synchronism. Appropriate action as described will follow to bring the slave and master yarns into synchronism or to keep them in synchronism.

If no index mark is detected by either of the two slave photosensors 1145 and 11511 at the time that the master index mark is detected, the slave logic decoder will apply a reset inhibit pulse to the reset gate 131 and a no-go pulse to the alarm circuit 134. The alarm circuit will sound an alarm, and the reset gate 131 will maintain the clutch previously selected at that same state until corrective action is taken by the operator.

DETAILED DESCRIPTION In the description of the detailed construction of the control the terms one" and zero" signal or pulse are used. A one" signal or pulse refers to a saturated positive voltage of +4.5 volts, and a zero" signal or pulse refers to a 0 volt signal.

In FIG. 12 the master logic decoder is shown. The signal from the first master photosensor lldb' is amplified by an amplifier 251, and applied through diode 253 to a lmicrosecond one shot circuit 255 which will produce through diode 257 on output terminal 259 the reset attempt pulse shown in FIG. 11 when the first master photosensor 11411 senses an index mark on the master index yarn. The reset attempt pulse is applied to terminal 203 in FIG. 13 where it is applied to the reset gate 131. The signal from the second master photosensor 11% is received by the master logic decoder 130 on terminal 261, amplified by amplifier 263, and applied through diode 265 to a 2microsecond one shot circuit 267 so that the one shot circuit 267 produces the speed evaluate pulse shown in FIG. 11 when the second master photosensor 1l5b senses an index mark on the master index yarn. The speed evaluate pulse from terminal 269 is applied to terminal 195 of the slave logic decoder 132 in FIG. 13. Neither one shot circuit 255 nor one shot circuit 267 will produce a pulse unless inputs from both master photosensors are received.

Nand circuits are used extensively throughout the control. Such nand circuits 179, 181, and 185 are shown in the slave logic decoder 132 in FIG. 13. Each nand circuit has a plurality of input terminals, labeled X, Y, and Z in these three nand circuits, and one output terminal. When all three input signals to a nand circuit are one (saturated +4.5 volts), the output is a zero" (a zero voltage). Conversely when one or more inputs to the nand circuit are zero" the output from the nand circuit is a one".

Amplifiers such as amplifiers and 191 receive an input from the left side to the center of the base, and produce an output from the right at the apex of the triangle. An amplifier amplifies the signal it receives and produces a signal of the opposite character. Thus if it receives a zero" signal, it produces a one" signal or pulse.

Two one shot circuits 255 and 267 are shown in FIG. 12 in the master logic decoder 130. Upon receiving a signal they produce a pulse of a predetermined width. Thus the reset attempt pulse produced by one shot 255 is l-microsecond long, while the speed evaluate pulse produced by the one shot 267 is 2 microseconds long. This difference between the pulses is shown in FIG. 11.

FIGS. 7, 8, 9, 10, and 10A show truth tables for the different elements of the control system. Each vertical column in each of the input columns indicates the input condition for the element identified, and each vertical column in each of the output columns indicates the output for that element identified for the combination of input columns in the corresponding horizontal column. Whenever an asterisk appears in a block of a column, this is an indication that the pulse or signal mentioned at the top of the column is present and reference is made, in the block where such asterisk appears to FIG. 11 to show the characteristics of any such pulse. In the remaining blocks the direct current level present at such a time is shown.

In the vertical input columns in FIGS. 7 and 8 labeled photosensor,"the notation BLACK indicates that the corresponding photosensor is sensing an index mark, and the notation WHITE indicates that the corresponding photosensor is not sensing an index mark. A BLACK signal is a "one" signal, and a WHITE signal is a "zero signal.

The signal from the first slave photosensor 11 3b is applied to terminal 171 of the slave logic decoder 132 in FIG. 13, and the signal from the second slave photosensor 11512 is applied to terminal 173 of the slave logic decoder 132 in FIG. 13. The input to terminal 171 from the first slave photosensor 1141; is inverted by amplifier 175 and applied to the Y terminal of nand circuit 177, applied to the Z terminal of nand circuit 179, applied to the Y terminal of nand circuit 181, inverted by nand circuit 1183, applied to the Y terminal of nand circuit 185, and connected through the WHITE light 187 to the +4.5 volt line. The input to terminal 173 from the second photosensor is connected through WHITE light 189 to the +4.5 volt line, inverted by amplifier 191 and applied to terminal X of nand circuit 185, inverted again by nand 193 and applied to terminal 2 of nand circuit 181, applied to terminal Y of nand circuit 179, and applied to terminal X of nand circuit 177.

The speed evaluate pulse as shown in FIG. 11 is received on terminal 195 of the slave-logic decoder from the master logic decoder 130, shown in detail in FIG. 12, and applied to terminal Z of nand circuit 185, terminal Y of nand circuit 181 and terminal X of nand circuit 179. v

The slave logic decoder 132 produces a yarn slow pulse from nand circuit 185, a yarn fast pulse from nand circuit 181 or a no-go pulse from nand circuit 179 (as shown in FIG. 11) according to the synchronism of the index yarn of the slave zone with that of the master zone as sensed by the master and slave photosensors in a manner to be explained.

These pulses are applied to the clutch selector 133 in combination with the application of a reset pulse from the reset gate 131 to select the accelerate, retard, or average clutch to either maintain the slave zone yarn in synchronism with the master zone yarn, or to bring the slave zone yarn into synchronism with the master zone yarn.

The yarn slow pulse from nand circuit 185 is applied to terminal X of nand circuit 195, and the yarn fast pulse from nand circuit 181 is applied to terminal X of nand circuit 197. The no-go pulse from nand circuit 179 is applied to terminal X of nand circuit 199 in the alarm circuit 134.

The output from the nand circuit 177 is a reset inhibit signal I which is applied to terminal X of nand circuit 201 in the reset gate 131. A reset attempt pulse received on terminal 203 from the master logic decoder 130 as shown in FIG. 11 is applied to terminal Y of nand circuit 201. The output from nand circuit 291 is applied to terminal Y of nand circuit 205 in the alarm circuit 134, to terminal Y of nand circuit 196, and to terminal Y of nand circuit 198. The output from nand circuit 196 is applied to terminal Y of nand circuit 195 and to terminal X of nand circuit 207. The output from nand circuit 195 to select the accelerate clutch is amplified by amplifier 211, energizes yellow light 213, and is delivered on output terminal 215 to select the accelerate clutch. The output from nand circuit 195 is also applied to terminal X of nand circuit 196.

The output from nand circuit 199 is applied to terminal Y of nand circuit 207 and to terminal Y of nand circuit 197. The output from nand circuit 197 is applied to terminal X of nand circuit 198, and also amplified by amplifier 217 and delivered on terminal 219 to select the retard clutch, and energizes yellow light 221.

The inputs to nand circuit 207 cause an output applied to nand circuit 269, amplified by amplifier 223 to select the average clutch by an output on terminal 225 and to energize the green light 227.

In the alarm circuit 13d the output from nand circuit 205 is applied to terminal Y of nand 199 and the output from nand 199 is applied to terminal X of nand 205. The output from nand 199 is also amplified by the alarm amplifier 229 to energize the red light 231 and passes through diode 233 to energize the audible alarm relay from terminal 235.

Each of the amplifiers 211, 217 and 223 are connected to a +l2 volt buss 237 and to an automatic buss 239. The accelerate clutch output terminal 215 is connected to an accelerate buss 241, and the retard clutch output terminal 219 is connected directly to a retard bus 243. A rotary switch 245 is connected to the common buss 2 37 and may be connected to either the automatic buss 239, the accelerate buss 241, the retard buss 243, or to an off position which is connected through a normally open switch 247 to an output terminal 249, which may be connected to a brake as hereinafter described. When the rotary switch 247 is connected to the off position 246 and the normally open switch 247 is closed, a brake mechanism, as described below, is energized to lock the feed rolls of the slave zone. When the rotary switch 245 is connected to the retard buss 243, the retard output terminal 219 is selected by itself; and when the rotary switch 245 is connected to the accelerate buss 241, the acclerate buss output terminal 215 is selected by itself. When the rotary switch 245 is connected to the automatic buss 239, the clutch output terminal selected is dependent on the inputs from the slave logic decoder to the clutch selector 138 in a manner to be described.

OPERATION OF CONTROL The operation of the control will be described for four specific conditions of the master index yarn and the slave index yarn. The first description will be where the master and slave index yarns are in synchronism with each other, the second will be when the slave index yarn is fast, the third when the slave index yarn is slow, and the fourth when there is no indication of the relationship of the slave index yarn with the master index yarn, i.e. no specific indication of whether the slave index yarn is fast or slow. In the first condition the average clutch will be energized, in the second when the slave index yarn is too fast the retard clutch will be energized to slow down the slave yarn, in the third condition when the slave yarn is too slow the accelerate clutch will be energized to speed up the slave yarn, and in the fourth condition an alarm will be sounded so that corrective action can be taken that cannot be taken by the control.

AVERAGE CLUTCH SELECTION The first situation occurs when the master index yarn and the slave index yarn are in synchronism. The first and second master photosensors 1 14b and b' sense the presence of an index mark on the master index yarn, thereby applying signals to terminals 250 and 261, FIG. 12, of the master logic decoder 130, which are both amplified by amplifiers 251 and 263, respectively, and applied to one shot circuits 255 and 267. When both photosensors sense the index mark, the one shot 255 produces a l -microsecond reset attempt pulse, FIG. 11, which is applied to terminal Y of the nand circuit 201 in the reset gate 131 in FIG. 13. The reset attempt pulse is a one" pulse. One shot circuit 267 produces a 2 -microsec0nd speed evaluate pulse, FIG. 11, which applies a one" pulse to terminal Z of nand 185, terminal X of nand 181, and terminal X of nand 179 in the slave logic decoder 132 in FIG. 13.

BLACK one signals are applied to first and second slave photosensor inputs 171 and 173 of slave logic decoder 132, FIG. 13, at this time as there is an index mark on the slave index yarn at the same time that there is an index mark on the master index yarn and both the first and second slave photosensors 11 3b and 115b sense an index mark at this time as the slave index yarn is in synchronism with the master index yarn. The one" signal from the first slave photosensor 1141b received on terminal 171 is inverted and amplified by amplifier 175 and applied as a zero signal to terminal Y of nand 177, terminal Z of nand 179, terminal Y of nand 181, and inverted by nand 183 and applied as a one" signal to terminal Y of nand 185. The BLACK one signal from the second slave photosensor 11512 is inverted and amplified by amplifier 191 and applied as a zero" signal to terminal X of nand circuit 177, terminal Y of nand 179, terminal X of nand 185, and inverted to a one signal by nand 193 and applied as a one" signal to terminal Z of nand 181.

The speed evaluate pulse has applied a one" signal to terminal X of nand 179, terminal X of nand 131, and terminal Z of nand at this time.

Nand circuit 185 has a zero signal applied to its X terminal at this time so that it continues to produce a one" signal which is applied to terminal X of nand circuit 195 in the clutch selector 138. Previously, other terminals of nand circuit 195 had zero signals applied thereto so it produced a one signal, thus there is no change in the output of nand 135.

Nand circuit 181 has a zero" signal applied to its Y terminal at this time so that it continues to produce a one signal which is applied to terminal X of nand circuit 197. This is no change.

Nand circuit 179 has zero" signals applied to its Y and Z terminals at this time so that it applies a one signal to terminal X of nand circuit 199 in the alarm circuit 134. This is no change as the speed evaluate line 195 previously applied a zero" signal to terminal Z ofnand 179.

Thus, the slave logic decoder has neither produced a yarn slow pulse, a yarn fast pulse, or a no-go pulse, and this is proper as the slave and master index yarns were in synchronism.

The nand circuit 177 now applies a one" signal to terminal X of nand circuit 201, The conditions established as described above are tabulated in FIG. 8 for the BLACK, speed evaluate pulse inputs. All four outputs are at 4.5 volts, or as we have termed it, at a one signal.

Reset nand circuit 201 with a one signal applied to its Y terminal and a one signal applied to its X terminal now produces a Zero" signal which is applied to terminal Y of nand circuit 205, terminal Y of nand circuit 196, and terminal Y of nand circuit 198.

First taking the alarm circuit, terminal X of nand circuit 199 continues to have a one" signal applied to its X terminal, so that nand circuit 199 applies a zero signal to terminal X of nand circuit 205. Nand circuit 205 has thus applied a one signal to terminal Y of nand 199. Thus, when a zero" signal is applied to terminal Y of nand 205, no change occurs in the alarm circuit 134.

Nand circuits 1.95 and 197 have one signals applied to their X terminals. Assuming that nand circuits 196 and 198 produce one signals applying one signals to the Y terminals of nand circuits 195 and 197, nand circuits 195 and 197 normally apply zero signals to the X terminals of nand circuits 196 and 198, so that nand circuits 196 and 198 normally apply one" signals to terminals X and Y, respectively, of nand circuit 207. The resulting zero" signal from nand 207 is inverted by nand 209 to a one signal and amplified by amplifier 223 to select the average clutch to keep the feed of yarns to the slave zone in synchronism with the feed of yarns to the master zone. The selection of the average clutch after the retard or accelerate clutch has been selected will be described later.

RETARD CLUTCH SELECTION The second situation occurs when the slave index yarn is too fast. The first and second master photosensors l14b and 11512 sense the presence of an index mark on the master index yarn applying signals to terminals 250 and 261 in FIG. 12 to produce the reset attempt pulse and the speed evaluate pulse in the same manner as described previously and as shown in FIG. 11. As the slave index yarn is too fast, the index mark has passed the first slave photosensor 114b but still confronts the second slave photosensor 115b. Thus, referring to FIG. 8, the first slave photosensor is WHITE applying a zero" signal to terminal 171 in FIG. 13, and the second slave photosensor is BLACK applying a one signal to terminal 173 in FIG. 13. The zero" signal received on terminal 171 is inverted by amplifier 175 to a one" signal, applying a one signal to terminal Y of nand 177, terminal Z of nand 179, terminal Y of nand 181, and is inverted by nand 183 to a zero signal and applied as such to terminal Y of nand 185. The one" signal received by terminal 173 is inverted by amplifier 191 to a zero" signal applying a zero signal to terminal X of nand I77, terminal Z of nand 179, terminal X of nand 185, and inverted by nand 193 and applied as a one" signal to nand 181.

The speed evaluate pulse shown in FIG, 11 is a positive "one signal at this time so that a one signal is applied to terminal Z of nand 185, terminal Z of nand 181 and terminal X of nand 179.

Nand circuit 181 thus has one signals applied to all three of its terminals so that it produces a zero yarn fast pulse at this time indicating that the slave index yarn is traveling too fast and must be slowed down. This zero" pulse from nand 181 in the slave logic decoder 132 is applied to terminal X of nand circuit 197 in the clutch selector 138.

The condition is now set forth in FIGv 10 for the clutch selection with a yarn fast pulse present, and no yarn slow pulse. As previously described, the reset attempt pulse shown in FIG. 11 causes a reset zero" pulse shown in FIG. 11 to be applied to terminal Y of nand 198. As described previously, the yarn slow pulse goes to a one" signal at the time that the speed evaluate pulse goes to a "zero signal for the zero signal applied to terminal X of nand 181 causes nand 181 to produce a one" signal again. The reset pulse applied to terminal Y of nand 198 lasts for l microsecond while the yarn fast pulse lasts for 2 -microsecond in the manner described.

The condition before the yarn fast pulse is applied is that terminals X and Y nand circuit 197 both have one signals applied thereto to produce a zero" signal which is applied to terminal X of nand 198. Terminal Y of nand 198 has a one" signal applied thereto.

The application of the zero" yarn fast pulse to terminal X of nand 197 causes nand 197 to produce a one signal which is amplified and delivered on the retard output terminal 219 as a retard clutch pulse to cause the retard clutch to be energized engaging the retard shaft 82 of FIG. 5. The slave zone feed rolls are then moved at a slower speed than previously, at least until the next index mark on the master index yarn is sensed to again determine the relative position of the slave index yarn in relation to the master index yarn.

The one" signal from nand 197 is also applied to terminal X of nand 198, and the reset pulse applied to terminal Y of nand 198 is a zero signal at this time so that nand 198 continues to produce a one signal which is applied to terminal Y of nand 197 to keep nand 197 producing the one signal to energize the retard clutch. The one" signal produced by nand 198 is also applied to terminal Y of nand 207, and as nand 207 has a one signal applied to its X terminal nand 207 continues to produce the zero signal which is inverted by nand 209 to a one to energize the average clutch pulse for a moment. However, when the reset zero" signal applied to terminal Y of nand 198 goes back to a one" signal, it causes nand 198 to produce a zero signal at this time so that nand 207 changes from a zero" output to a one and nand 209 produces a zero" signal which does not select the average clutch at this time. Nand 197 continues to produce a one signal at this time to produce the select retard clutch signal from terminal 219. The one signal from nand 197 continues when the yarn fast pulse goes to a one signal as nand 197 then has a one" signal applied to its X terminal and a zero signal applied to its Y terminal.

AVERAGE CLUTCH SELECTION If subsequently the next condition is that the slave and master index yarns come back into synchronism the conditions will be as described previously with one" signals applied to terminal X of nands 19S and 197. A reset zero signal is applied to terminal Y of nands 196 and 198. Nand 196 has continued to apply a one" signal to terminal X of nand 207, however nand 198 has been applying a zero signal to terminal Y of nand 207 as the retard clutch has been selected. The zero signal applied to terminal Y of nand 198 however, causes nand 198 to produce a one" signal instead of a zero" signal at this time and apply that one" signal to terminal Y of nand 207 and to terminal Y of nand 197. Nand 197 with a one" signal applied to both terminals at this time starts to produce a zero" signal instead of a one" signal so that the retard clutch is no longer selected. Instead with the application of one" signals to both terminals of nand 207 at this time, nand 207 produces a zero" signal which is inverted by nand 209 to a one" signal to select the average clutch.

If another yarn fast pulse is applied to nand 197, or a yarn slow pulse applied to nand either the clutch retard or clutch accelerate signal will be generated instead of the clutch average signal.

1 ll ACCELERATE CLIJTCI-I SELECTION The selection of the accelerate clutch is carried out in a similar manner to the selection of the retard clutch. In such a selection the slave index yarn is moving too slow in relation to the master index yarn so that first photosensor 114k senses the index mark on the slave index yarn, but the second photosensor 115b does not sense the index mark on the slave index yarn at the time that the master photosensors sense the index mark on the master index yarn. Therefore, the one" signal sensed by the first photosensor l14b and the zero signal sensed by the second photosensor 115b cause the generation ofa zero yarn slow pulse from nand circuit 185 with the application of one signals to nand circuit 185. The application of a zero" signal to nand 195 causes nand 195 to produce a one ac- :elerate clutch signal in the same manner that nand 197 produced the clutch retard signal, thus, selecting the ac- :elerate clutch.

ALARM SELECTION When the master photosensors sense an index mark on the master zone index yarn, but neither the first nor the second slave photosensors sense the presence of an index mark on the slave zone index yarn at the same time, any suitable alarm and light are energized.

Referring again to FIG. 13, if neither the first nor the second photosensor input terminals 171 and 173 receive a one" signal at the same time that the reset attempt pulse is applied to terminal Y of nand 201, the zero signals recieved on both terminals 171 and 173 are inverted by amplifiers 175 and 191, respectively, to one signals, thereby applying one signals to both terminals of nand 177. Nand 177 thus applies a zero" signal to terminal X of nand 201. The one" reset attempt pulse is applied to terminal Y of nand 201 at this time resulting from the sensing of an index pulse on the master index yarn in the manner described previously. The control is unable to take corrective action as described previously, as there is no indication of the position of the slave index yarn in relation to the master index yarn. The reset nand 201 applies a one" signal to terminal Y of nand 205. One signals are also applied to terminals Y and Z of nand 179 and the speed evaluate pulse applies a one signal to terminal X of nand 179, so that nand 179 produces a no-go pulse applying a zero" pulse to terminal X of nand 199. Nand 199 therefore produces a one alarm pulse which is amplified by amplifier 229 to energize the red alarm light 231 and delivers an alarm pulse to the alarm relay to energize an alarm 134. The alarm remains energized, and the previously selected clutch remains energized until corrective action is taken.

A detailed description of the energization of the average, the retard, and the accelerate clutch of slave zone No. 2 has been given. Likewise, a description of the energization of the alarm has also been given.

It will be appreciated that the circuitry of FIG. 13 may be repeated to accommodate as many slave zones in addition to zone No.2 as may be desired.

The master zone feed rolls may be driven at either a fast speed, a slow speed, or an average speed by the selection of the rotary switch 246, FIG. 12. The selection of the rotary switch 246 at either one of the three operating positions (average, fast, or slow) selects a corresponding output ter minal (average clutch terminal 248, fast clutch terminal 252, or slow clutch terminal 254). A corresponding light is lit to in- Jicate the speed at which the master zone feed rolls are being Iriven. A green light 256 is lit to indicate the average speed, a yellow light 258 is lit to indicate the fast speed, and another yellow light 260 is lit to indicate the slow speed. The rotary switch 246 may also select the off position to remove power from the master zone feed rolls, and a corresponding red light 262 is lit to indicate the fact that the master zone feed rolls do not have power applied thereto.

A four position manually operated switch 245, FIG. 13, may be actuated as desired to place the clutch selector of the slave zone No. 2 under automaticcontrol, or to manually select the accelerate or retard clutch of such zone. The switch may also be set to anoff position to remove power from the slave zone No. 2. Any suitable brake apparatus may be utilized in each of the zones to allow the feed rolls for any such zone to be braked in their off position. Such a brake apparatus may take the form of an idler sprocket wheel similar to the sprocket wheel 89, FIG. 5, and a magnetic brake carried by a stud on each of the frame members 72 such that when a brake switch 2&7 or 262 is closed the magnetic brake will be energized to lock the idler wheel and its associated chain in a fixed position.

Although in the present embodiment I describe my invention in connection with its application to the feeding of yarn to a multiple needle tufting machine, it will be appreciated by those skilled in the art that the invention would find use in connection with apparatus other than tufting machines, for example, pile forming knitting machines.

Iclaim:

1. Apparatus for feeding yarns to the needles of a multiple needle tufting machine comprising, a tufting machine including multiple needles, means for feeding a first yarn having a lengthwise repeating pattern thereon to one of said needles, means for feeding a second yarn having a lengthwise repeating pattern thereon to another of said needles, and means for synchronizing the pattern on said first and second yarns in a predetermined manner as said yarns are fed to said needles.

2. Apparatus for feeding yarns to the needles of a multiple needle tufting machine comprising, a tufting machine including multiple needles, means for feeding a first group of yarns having a lengthwise repeating pattern thereon to certain of said needles, means for feeding a second group of yarns having a lengthwise repeating pattern thereon to others of said needles, and means for synchronizing the transverse alignment of the pattern on said second group of yarns with the pattern on said first group of yarns as said first and second groups are fed to said needles.

3. Apparatus for feeding pile yarns to a multiple needle tufting machine comprising, a tufting machine including multiple needles, means for moving a first group of patterned yarns, said first group of yarns including an index yarn having spaced apart index marks thereon, means for moving a second group of patterned yarns, said second group of patterned yarns including an index yarn having spaced apart index marks thereon, and means for synchronizing the transverse alignment of the index marks on said index yarns to synchronize the transverse alignment of the patterns on said first and second groups of yarns as said pile yarns are fed to said tufting machine.

4. Apparatus for feeding a plurality of groups of yarns to the needles of a multiple needle tufting machine comprising, a tufting machine including multiple needles, first means for feeding a first group of patterned yarns to certain of said needles, second means for feeding a second group of patterned yarns to others of said needles, a first index yarn moved by said first means, a second index yarn moved by said second means, a first sensing means for sensing said first index yarn, a second sensing means for sensing said second index yarn, means for comparing the output from said first sensing means with the output from said second sensing means and producing a signal indicative of the relative transverse registration of the pattern on said first group of yarns with the pattern on said second group of yarns, and means responsive to said signal from said comparing means for controlling the speed of said second feeding means.

5. The invention of claim 4 wherein said second feeding means includes apparatus for driving said second feeding means at a normal speed, at a speed slower than normal, and at a speed faster than normal, and said means responsive to the said signal causes said second feeding means to be driven at said normal speed when said index yarns are in transverse alignment, at said slower than normal speed when said second index yarn leads said first index yarn, and at said faster than normal speed when said second index yarn lags said first index yarn.

6. The invention of claim wherein said second index yarn has a plurality of spaced apart index marks thereon, said second sensing means includes a first sensing element and a second sensing element spaced a predetermined distance apart such that said first and second sensing elements may sense one index mark at the same time, said first index yarn has a plurality of spaced apart index marks thereon, said first sensing means includes a first sensing element and a second sensing element spaced a predetermined distance apart such that said first and second sensing elements of said first sensing means may sense one index mark at the same time.

7 The invention of claim 6 wherein means are provided for actuating an alarm when said second sensing means fails to sense an index mark at the same time that said first sensing means senses an index mark.

8. Means for controlling the feed of yarn to the needles of a multiple needle tufting machine comprising, a tufting machine including multiple needles, means for feeding a first yarn having a lengthwise pattern repeat thereon to one of said needles, means for feeding a second yarn. having a lengthwise pattern repeat thereon to another of said needles, means for determining the displacement of the pattern on the first of said yarns relative to the pattern on the second of said yarns, and means responsive to said determining means for synchronizing the transverse registration of the pattern on said first yarn with the pattern on said second yarn as all of said yarns are fed to said needles.

9. Apparatus for feeding pile yarns to a pile forming machine comprising, means for feeding a first yarn having a lengthwise repeating pattern thereon to said pile forming apparatus, separate means for feeding a second yarn having a lengthwise repeating pattern thereon to said pile forming apparatus, and means for synchronizing the transverse alignment of the pattern on said first and second yarns in a predetermined manner as said yarns are fed to said pile forming apparatus.

10. Apparatus for withdrawing yarns from plural sources for presentation to the needles of a :multiple needle tufting machine comprising, means for withdrawing a first group of patterned yarns, said first group of yarns containing an index yarn having index marks at spaced] intervals thereon, and means for withdrawing a second group of patterned yarns, said second group of yarns containing an index yarn having index marks at spaced intervals thereon, and means for synchronizing the transverse alignment of the index marks on the index yarn in said second group of yarns with the index marks on the index yarn in said first group of yarns as both of said groups of yarns are withdrawn from said plural sources.

11. A method for controlling the feed of yarns to a pile forming apparatus comprising the steps of withdrawing from plural sources yarn having lengthwise pattern indicators at spaced intervals thereon, feeding certain of said yarns from each source to the pile forming apparatus, determining the relative position of pattern indicators on others of said yarns from each source, and thereafter controlling, in a predetermined manner, the rate of feed of some of the yarns from one or more sources being fed to the pile forming apparatus so as to synchronize the transverse alignment of the pattern on said yarn.

12. The method of claim 11 wherein all of said yarns are fed to the pile forming apparatus.

13. A method for controlling the feed of yarns to the needles of a multiple needle tufting machine comprising the steps of withdrawing from plural sources yarn having lengthwise pattern indicators at spaced intervals thereon, feeding certain of said yarns from each source to said needles, determining the relative position of pattern indicators on others of said yarns from each source, and thereafter controlling, in a predetermined manner, the rate of feed of some of the yarns from one or more sources being fed to said needles so as to synchronize the transverse alignment of the pattern on said yarn.

14. The method of claim 13 wherein all of said yarns are fed to said needles. 

